Battery management system and apparatus

ABSTRACT

The invention relates to the management of large stationary batteries. The invention is a comprehensive process for the management of stationary batteries that are used for backup power and are deployed in widely dispersed locations. The OMS™ (Optimization Management System) solution is comprised of Mega-Tags (preferably serialized bar-coded identification labels), a battery testing and data acquisition device, and web-based software. The OMS™ system employs algorithmic testing to determine whether a particular battery unit needs to be replaced or whether it can be advantageously redeployed. These components work together to provide a platform for managing a large number of perishable, expensive, and geographically dispersed assets.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of, and claims priority to,U.S. application Ser. No. 10/749,004, filed Dec. 30, 2003 now U.S. Pat.No. 7,003,431, which is incorporated herein by reference in itsentirety.

BACKGROUND OF THE INVENTION

The invention relates to the management of large stationary batteries.The invention is a comprehensive system and apparatus for the managementof stationary batteries that are used for backup power and are deployedin widely dispersed locations. The OMS™ (Optimization Management System)solution is comprised of battery tags (sometimes referred to herein as“Mega-Tags,” which are preferably serialized bar-coded identificationlabels), a battery testing and data acquisition device, and the OMS™web-based software. These components work together to provide a platformfor managing a large number of perishable, expensive, and geographicallydispersed assets.

The invention solves many of the unique problems associated withbatteries. Batteries are perishable. That is, they have a limitedshelf-life and a limited useful life. Stationary industrial batteries ofthe type that benefit from the OMS™ solution are typically sealedlead-acid batteries. These electromechanical devices typically must beinstalled within 6–10 months from date of manufacture or else they needto be recharged. In addition, most of these batteries are designed for a10 year useful life, but in the field generally last only from 2–6years. The discrepancy between design life and actual life is a majorproblem for users of these batteries.

Stationary batteries are also large, heavy and expensive. They aregenerally used in large numbers to provide the required backup power.Keeping track of these devices therefore provides an additional assetmanagement challenge.

Batteries contain hazardous substances which are toxic to theenvironment. There are strict rules and regulations governing thedisposal of batteries. These rules and regulations also containdocumentation requirements. Users must be able to provide adequate proofof compliance or face severe penalties. Documentation is a highlymanual, expensive process, and most compliance is done as anafterthought.

Batteries are generally deployed in strings of two or four 12-voltunits, in strings of three 12-volt units, or in strings of six or twelve2-volt units, in order to power 24 volt, 36 volt or 48 volt equipment.This electrical combination of batteries compounds the difficulty ofmanaging these storage devices. In sum, managing stationary batteries isdifficult, and is generally not a core competency of most businessesthat use these batteries.

BRIEF SUMMARY OF THE INVENTION

The OMS™ (Optimization Management System) tracks batteries fromcradle-to-grave. It enables companies with large deployments ofstationary batteries to manage assets that are both perishable andgeographically dispersed, and therefore difficult to mange. OMS™ iscomprised of the following items which work together to provide thisunique service: First, Mega-Tags (preferably serialized bar-codedidentification labels) are affixed to every individual battery. Abattery testing device (preferably the BatteryCorp BC-T2000 or similartesting device), which contains both a bar code reader and a serial portto connect to a PC, scans a Mega-Tag and then performs its test on anygiven battery. Batteries are usually deployed in “strings” ofelectrically interconnected units to increase voltage and output power.Each battery test data point is stored along with the unique identifiervalue associated with the individual battery unit. The user connects theBatteryCorp BC-T2000 (or similar testing device) to the serial port of aPC with the provided null-modem cable. Linking software (preferably theT2000 Link software) facilitates the transfer of data from the testingand data acquisition device to the PC internal storage. The user thenlogs into the proprietary website and clicks on the Upload Data icon;OMS™ then uploads the specified data file to a proprietary web server.The web server processes the data file, storing the pertinent data inthe appropriate tables of the OMS™ database.

The invention provides comprehensive reporting and analysis options.This includes both operational and financial reports, as well asdetailed recycling documentation. The OMS™ auto-notification featureemails reminders to customer technicians that testing is required. Theseemails are based upon customer-defined business rules. (Testing timeperiod interval and escalation procedure, by business unit.)

The OMS™ solution enables users of stationary batteries to manage allaspects of their battery deployments. It is the only available tool thatautomates the process of uniquely identifying, testing, evaluating andreporting on the state of health of any given battery. It providesinformation on installation, deployment, testing, recycling anddestruction. It provides information in both aggregate and detailformats, for both internal and external use.

Its advantages are many. It enables users to manage large, widelydispersed deployments of stationary batteries in an efficient and costeffective manner. It increases the reliability of the backup powerplant, because the operator now has information on the performancestatus of the batteries. The system also facilitates the safe recyclingof potentially toxic devices, while reducing the risk of non-compliancewith governmental regulations.

The specific application of OMS™ that is the replacement methodinvention is that OMS™ applies customer business rules to the uploadedtest data, and automatically instructs the technician as to whichspecific battery or batteries, by serial number, need to be replaced.The technician no longer has to make any decisions, thus removingsubjectivity from the process. OMS™ both produces reports which detailthe specifics of the batteries to be replaced, and it sends automatedemail messages to the appropriate technician, with the relevantinstallation instructions.

Another object of the invention is to provide a battery managementsystem easily applied to existing batteries without modification of thebatteries, and that easily accommodates a varied inventory of batteriesfrom different manufacturers.

Other objects and advantages will be more fully apparent from thefollowing disclosure and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and objects of this invention andthe manner of obtaining them will become apparent and the inventionitself will be best understood by reference to the following descriptionof an embodiment of the invention taken in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a representation of a tag for use with the present invention;

FIG. 2 is a perspective view of a battery unit with a tag associatedwith the battery;

FIG. 3 is a view of a battery testing and data acquisition device foruse with the present invention;

FIG. 4 is a flow diagram illustrating the process of the presentinvention;

FIG. 5 is a flow diagram illustrating the battery replacementmethodology;

FIG. 6 is a flow diagram illustrating a sample application of thereplacement methodology.

DETAILED DESCRIPTION

The invention provides and coordinates battery testing, maintenance,installation, fulfillment and disposal of batteries, and is capable ofperforming these functions over a wide geographical area. It seamlesslyintegrates these services via the BatteryCorp BC-T2000 tester and theOMS™ web based platform. This innovative solution helps companiesimprove their backup power systems while reducing costs.

FIG. 1 shows a preferred Mega-Tag to be associated with an individualbattery. The tag is associated with a particular battery unit, so thatthe unique identification number embedded in the tag is consistentlyassociated with that particular battery. Preferably to assure suchcontinued association, the Mega-Tag is affixed to the exterior casing ofthe battery (5) with an adhesive, as shown in FIG. 2.

Mega-Tags are preferably bar coded labels that contain a uniqueidentifier for the associated battery. The tag shown in FIG. 1 has,preferably, the following information: (1) the service provider name andtelephone number; (2) the bar code of a unique identification number;(3) the battery model; and (d) the unique identification number in humanreadable form. Because of the preferred inclusion of human readableinformation in conjunction with the bar code identification number, theMega-Tag is preferably affixed where it can be viewed and scanned by ahuman operator without dislocating the battery.

FIG. 3 shows a testing and data acquisition device for use with thepresent system. The device shown is a BatteryCorp BC-T2000 device.However, different testers could be used, but such testers should beable to import data from a bar code reader, and have the ability toexport data files. The bar code scanner or reader is preferably indirect communication with the battery testing device for ease of use andreliable interface. This is preferably accomplished by use of a port (6)for a bar code reader and for connection to a computer. Also shown inFIG. 3 are ports for two testing probes (7), and A/C current in port (8)and an on/off switch (9). The data files can be in a number of formats,since the invention is a flexible platform with the ability to interfacewith data files in a number of formats.

In particular, the battery tester should be able to store test resultsin memory, associating each test with the pertinent unique scannedidentifier. The tester also should be able to output the test results inan industry-standard file format, such as ASCII text or Excel XLS. Thetester should be able to perform impedance or conductance testing (IEEEapproved technologies). Many companies that utilize stationary batteriesperform impedance or conductance tests.

In an alternative embodiment, the tester may operate with an infra-redthermometer, either integrated with the battery tester or otherwise incommunication with the tester. The thermometer would read thetemperatures of individual batteries, and the temperature associatedwith the unique identifier for that particular unit. Such a thermometerwould provide additional information concerning the subject battery unitthat would be read, uploaded and stored. Such a thermometer wouldobviate the need for a separate thermometer to record ambienttemperature surrounding the battery units, which is stored along withthe battery test data, and provide a more accurate reading of individualunit temperatures.

The testing device files preferably have the following headerinformation. First, a Location Code is included with the file. This is acode that links the database of the invention, indicating the locationof the battery. Second, the ambient temperature is stored along with thetest information, because battery temperature is correlated with lifeexpectancy. This information is also required by many batterymanufacturers for warranty claims.

The testing device files preferably have the following detailinformation. First, there is a Unique Identifier that identifies theindividual battery unit. Second, the date and time of the test areincluded in the file. Third, the test value, which is the individualbattery unit test result, typically either an impedance value or aconductance value. It is the key indicator of the battery's health. Thegreater the impedance or the lower the conductance (they are inversemeasurements of the same attribute) the poorer the state of health ofthe battery. Fourth, a strap test value, which is optional. Straptesting is a test of the interconnection between the current batteryitself and the next battery in sequence (in the string). Fifth, avoltage is included, which is the voltage measurement of the battery.Voltage is another indicator for battery health and is also an indicatorof the status of the device which is used to charge the battery.

Database management is another component of the present invention. Eachbattery test data point is stored along with the unique identifier valueassociated with the individual battery unit. This enables trend analysisreporting and individual battery detail reporting.

In operation, the user connects the battery testing device to the serialport of a PC with a null-modem cable, a standard computer peripheraldevice which is readily available. The linking software facilitates thetransfer of data from the testing and data acquisition device to the PCinternal storage. Typically, the user clicks the “Transfer” buttondisplayed on the graphical user interface (GUI) of the software. Theresponse will be “Waiting for data.” Prompts on the battery tester willguide the user to the menu option for downloading the data.

The user then logs in to the proprietary service provider website. Theuser will then click on the Upload Data icon displayed within the GUI.The linking software then uploads the specified data file to aproprietary web server. The web server processes the data file, storingthe pertinent data in the appropriate tables of the OMS™ database.

Data elements stored include:

-   -   a. Unique ID    -   b. ID of the user who performed the test    -   c. Test date and time    -   d. Test type (Impedance or Conductance)    -   e. Test measurement value    -   f. Strap measurement value if applicable    -   g. Voltage    -   h. Ambient temperature

The invention then generates comprehensive reporting and analysis,including preferably the following:

-   -   a. Battery Test History (detail by location)    -   b. Battery Test Summary (overview of tests and results)    -   c. Untested Batteries (verification tool)    -   d. Battery Installation Aging (based upon installation date)    -   e. Performance Status Report (analysis which groups batteries        based upon user-defined status criteria for “pass”, “fair”,        “warning” and “fail”)    -   f. Replacement Forecast (analysis based upon user-defined        criteria to estimate costs of upcoming replacements)

Auto-notification is another part of the present invention. This featureis based upon customer-defined business rules. These rules typicallytest interval and escalation procedure, automatic battery replacementintervals and escalation procedures. These business rules can bespecified by customer-defined business units. Business units might begeographical areas, product line groupings, etc. This providesconsiderable flexibility for the user in how to utilize the automatednotification process. All notifications are preferably made via email orother electronic transmission means.

FIG. 4 provides a high-level overview of the process of the presentinvention. The OMS™ software will send an automated email notificationto the pertinent technician that various locations require batterytesting. This process is called Auto Notification. The person that isinformed of the required testing can be either an internal (i.e.employee of the customer company) or an outsourced (third party)technician. This Auto Notification feature is not required forfunctioning of the present invention, since users may utilize the OMS™software with this feature disabled, and set up their testing scheduleseparately.

The technician tests the batteries with the batter tester and uploadsthe data via a network connection, preferably a global computer networksuch as the Internet, to the OMS™ proprietary database, preferablylocated on a server. Upon receipt of uploaded data files, the OMS™software immediately processes the data and sends an automated report(Auto Report) back to the technician. The report will indicate whetherthe batteries all “Passed,” or if any “Failed” the test. The report mayalso provide instructions to the technician on whether or not to replaceany given battery or all batteries, depending upon the business rulesfor that customer (Auto Replacement). If Auto Replacement is enabled,the OMS™ software will route the appropriate information to thepertinent installation technician. The OMS™ software may providerecycling documentation, so that batteries being replaced may beproperly recycled.

An Auto Report is generated via the battery tester and sent via anetwork connection, preferably through a global computer network such asthe Internet, to the OMS™ proprietary software and to the OMS™ database.

The OMS™ software platform has been built using programming tools fromMicrosoft. The integrated development environment (IDE) includesproductivity boosting features such as automated syntax management, apowerful editor, line-by-line debugging, graphical design tools(including visual classes and subclasses), and integrated databaseaccess. The platform is fully object-oriented, offering developers thebenefits of full inheritance, encapsulation and polymorphism. Thisdramatically reduces design, coding, and testing times, producing ahighly efficient rapid application development (RAD) environment.

The methodology employed in the OMS™ platform can be referred to asbusiness function modeling (BFM). The entire orientation of thedevelopment effort revolves around the business rules and processes.This may also be referred to as an object functional model. Eachfunction encapsulates a particular business task, yet from a developmentpoint of view it also inherits any and all system functions necessary toperform the intended task.) For example, a purchase order object wouldaccept the request, access the necessary data, employ all pertinentbusiness rules, validate the posted data, update the database, andgenerate a response—all within a single software object. This is a majorarchitectural advantage.

FIG. 5 shows the Replacement Methodology Framework that comprises thesteps of

-   Developing standards with the customer-   Converting standards into OMS™ business rules-   Acquiring data, identifying the sites and batteries-   Creating Mega-Tags for every individual jar/battery-   Testing the batteries and uploading the data to OMS™-   Applying the business rules to the test results-   Electronic notifying of replacement with instructions to technician    keyed to the battery to be replaced.

FIG. 6 also shows a set of sample rules created for the replacementdetermination method, together:

The general rule is to test batteries every X months, X being a valueassigned in view of the particular type of batteries. The X value can beautomatically scheduled by the OMS software. The sample value for X isshown as 12 months. Common values for X are 3 months, 6 months, and 12months.

The second value X is an age value, where the business rule would be toreplace the battery if it is older than X months. The sample value for Xis 60 months, with the option under the rule to not replace the batterybased on the battery's age.

The test results for the individual battery are uploaded into the OMSsoftware. The preferred status options generated from an application ofthe business rules to the test results will be: Pass; Fair; Warn; orFail. The test results are compared by OMS™ to a known benchmark for thepertinent battery type. Based upon the difference, in percent, betweenthe benchmark value and the actual test value, OMS™ makes thedetermination as to the status. For example, if a battery tests at 1.87milliohms and the benchmark is 1.0 milliohms, then the percentagedifference is 87% and the battery would Fail; if the battery tests at1.05 milliohms then the percentage difference is 5% and the batterywould Pass. The percentage criteria for determining the status arebusiness rule settings that are determined by the customer and inputinto OMS™. This methodology is employed for both types of ohmictesting—impedance and conductance. In FIG. 6, based upon the type ofbattery being tested and the business rule setting for Failure, theexample shows that a test result of 2.87 milliohms or higher wouldresult in OMS™ considering the battery to have a status of Fail. In FIG.6, the impedance value is set at 2.87 milliohms, and the system willissue a Fail message if the impedance value obtained from the testresults is greater than 2.87 milliohms.

FIG. 6 also shows a business rule based on the string average varianceobtained by the comparing the ohmic test value (either impedance orconductance) measured for a battery in a string to the averageconductance value for the battery string. In the sample, the system willgenerate a replacement notification signal if the conductance value forthe individual battery is 25% lower than the average conductance valueof the battery string.

Although the present system is fully automated within the limits of theproblems faced, a visual inspection of the battery should not beoverlooked. Such visual, on site examination is used to determinewhether adverse conditions exist that could affect battery life, safetyconcerns or cause possible environmental damage. Ordinarily, a batterywould be replaced if the inspection revealed leakage of electrolyte,cracking of the battery case or any other physical damage that mayimplicate the above concerns.

The Warn signal is a conditional message that allows the user todetermine if a battery should be replaced or not replaced. Oneconsideration is that if other batteries at the same location as thebattery in Warn status are to be replaced, it may be more economical andefficient to replace the Warn status battery with the others at the sametime. This concept also applies to string replacement, where an entirestring of batteries should be replaced if a predetermined percentage ofbatteries fail, or if substantially all of the batteries in the stringare of a predetermined age value. The sample shown in FIG. 6 shows anage value of 3 years based on the installation date, and a replacementmessage is generated if more than 40% of the batteries in a stringgenerate a Fail message or are at least 3 years old. This business ruleutilizes two settings that are determined by the customer andimplemented in OMS™: (1) the percentage of the string that is requiredto trigger the replacement, and (2) the age required to trigger thereplacement. Common values for the percentage range from 25–50% and forthe age range from 2 years to 4 years.

Finally, the OMS™ platform contains a rich set of connectivity tools. Itcan easily import/export data in various formats, from plain text todelimited files to Excel to XML. In fact, the battery tester uploadmodule accepts data in both text and XLS formats. OMS™ can also directlyaccess any ODBC compliant data source, such as Oracle, DB2 and otherdatabases. However, we expect that the XML classes in particular willfacilitate seamless communication between OMS™ and any related systems.

The specific products utilized to build OMS™

-   -   Microsoft Visual FoxPro 7.0 (IDE)    -   West Wind Web Connection (Base classes for web services)    -   Macromedia HomeSite (HTML/JavaScript editor; any can be used)    -   IDAutomation.com bar code fonts    -   Adobe Acrobat 5.0        Web Connect by West Wind Technologies is a framework of base        classes for building web applications. These classes perform all        low-level functions for authentication, request management,        session management, data formatting and output.

Since other modifications or changes will be apparent to those skilledin the art, there have been described above the principles of thisinvention in connection with specific apparatus, it is to be clearlyunderstood that this description is made only by way of example and notas a limitation to the scope of the invention.

1. A battery testing and replacement notification method comprising thesteps of: identifying a battery and a site for each identified battery;the battery having a plurality of attributes; creating a uniqueidentifier for each identified battery; generating a set of businessrules, the set of business rules comprising a set of baseline values forthe plurality of attributes associated with the battery; testing eachidentified battery to acquire test results, the test results comprisinga set of battery values for the plurality of the attributes associatedwith the battery; storing the set of business rules and the test resultsin a computer memory; loading the test results in the computer memory;comparing the set of baseline values of the business rules with thebattery values of the test results to create a report for the battery,the report being a readable computer file; generating a statusnotification signal dependent upon the report for the battery.
 2. Themethod of claim 1, further comprising the step of examining each batteryfor physical indicia of damage.
 3. The method of claim 1, wherein theplurality of attributes of the battery comprises an age value, animpedance value, and a conductance value.
 4. The method of claim 3,wherein the baseline value of the age attribute is within a range ofabout 24 to about 48 months.
 5. The method of claim 3, wherein thebaseline value of the impedance attribute is about 2.87 milliohms. 6.The method of claim 3, wherein the baseline value of the conductanceattribute is about a number 25% lower than an average of a batterystring.
 7. The method of claim 1, further comprising the step ofcompiling the test results for each battery on a string and calculatinga percentage of batteries that generate a replacement notificationsignal.
 8. The method of claim 7, further comprising the step ofgenerating a string replacement signal if the percentage of the stringof batteries that generate a replacement notification signal is greaterthan 40%.
 9. The method of claim 1, wherein the business rules furthercomprise an automated test signal to schedule battery testing at the endof a period.
 10. The method of claim 9, wherein the period is 12 months.11. The method of claim 1, wherein the step of generating a replacementnotification signal comprises instructions for battery replacement keyedto a battery unit to be replaced.
 12. The method of claim 1, wherein theinstructions for battery replacement further comprise recyclinginstructions.
 13. The method of claim 1, further comprising the step ofreplacing a battery if the battery is damaged.
 14. The method of claim1, further comprising the step of generating a replacement notificationsignal if other batteries are to be replaced at a same location.
 15. Abattery testing and replacement notification method comprising the stepsof: identifying batteries and a site for each identified battery;creating a unique identifier for each identified battery, the identifiedbattery having a plurality of battery values; testing each identifiedbattery to acquire test results and loading the test results in acomputer; generating a set of business rules; the set of business ruleshaving a plurality of baseline values; the plurality of valuescomprising an age value and an impedance value; applying die set ofbusiness rules to the test results of each identified battery;generating a replacement notification signal based on a comparison ofthe test results of the battery to the baseline values of the set ofbusiness rules.
 16. The method of claim 15, wherein the plurality ofbaseline values further comprises a conductance value.